CAMSHAFT INSTALLATION


  1. INSTALL CAMSHAFT BEARING CAP RH


    1. Apply a light coat of engine oil to the camshaft journals, camshaft housings and bearing caps.

    2. A01ES1NE01

      Install the No. 1 and No. 2 camshafts to the camshaft housing.

      Tech Tips

      Check the identification mark stamped on the camshaft.

      Item Mark
      for Intake Side NO. 1
      for Exhaust Side NO. 2

    3. Confirm the marks and numbers on the camshaft bearing caps and place them in their proper positions and directions.

    4. A01ENKSE02

      Temporarily install the 10 bolts in the order shown in the illustration.

  2. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH


    1. A01EOPTE01

      Make sure that the valve rocker arms are installed as shown in the illustration.

    2. A01ENFJE04

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

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      3.5 to 4.0 mm (0.138 to 0.157 in.)

      Note


      • Remove any oil from the contact surface.

      • Install the camshaft housing within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

    3. A01EP84E03

      Install the camshaft housing, and install the 18 bolts in the order shown in the illustration.

      Torque:
      for bolt A
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      except bolt A
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

      Note


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

      • Make sure that the knock pin of the camshaft is positioned as shown in the illustration before installing the camshaft housing.

    4. A01EQ1SE04

      Tighten the 10 bolts in the order shown in the illustration.

      Torque:
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }

      Note

      Thoroughly wipe clean any seal packing.

  3. INSTALL CAMSHAFT BEARING CAP LH


    1. Apply a light coat of engine oil to the camshaft journals, camshaft housings and bearing caps.

    2. A01EP3PE01

      Install the No. 3 and No. 4 camshafts to the camshaft housing.

      Tech Tips

      Check the identification mark stamped on the camshaft.

      Item Mark
      for Intake Side NO. 3
      for Exhaust Side NO. 4

    3. Confirm the marks and numbers on the camshaft bearing caps and place them in their proper positions and directions.

    4. A01ESJTE01

      Temporarily install the 10 bolts in the order shown in the illustration.

  4. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH


    1. A01EOPTE01

      Make sure that the valve rocker arms are installed as shown in the illustration.

    2. A01EPKNE01

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

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      3.5 to 4.0 mm (0.138 to 0.157 in.)

      Note


      • Remove any oil from the contact surface.

      • Install the camshaft housing within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

    3. A01EPSSE03

      Install the camshaft housing, and install the 18 bolts in the order shown in the illustration.

      Torque:
      for bolt A
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      except bolt A
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

      Note


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

      • Make sure that the knock pin of the camshaft is positioned as shown in the illustration before installing the camshaft housing.

    4. A01EPQME04

      Tighten the 10 bolts in the order shown in the illustration.

      Torque:
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }

      Note

      Thoroughly wipe clean any seal packing.

  5. INSTALL CRANKSHAFT TIMING GEAR KEY

    A01EN9W

    1. Install the timing gear key.

      Tech Tips

      The other timing gear key will be installed at a later step.

  6. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily install the crankshaft pulley bolt.

    2. Rotate the crankshaft so that the timing gear key is as shown in the illustration. Then using a wrench, rotate each camshaft so that the timing marks are as shown in the illustration.

      Note

      When the crankshaft or a camshaft is rotated excessively, the valves and pistons may interfere with each other.

    3. Remove the crankshaft pulley bolt.

      A01EOY1E01

  7. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY

    A01ES4KE04

    1. Install the chain tensioner with the 2 bolts.

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

    2. While raising up the No. 2 chain tensioner, insert a pin of 1.0 mm (0.0394 in.) into the hole to fix it in place.

  8. INSTALL NO. 1 CHAIN SUB-ASSEMBLY RH

    A01ERHYE01

    1. Align the No. 1 chain orange mark plate with the camshaft timing gear timing mark, and attach the chain to the gear as shown in the illustration.

    2. A01EO2QE03

      Align the No. 1 chain orange mark plate with the crankshaft timing sprocket timing mark, and attach the chain to the gear as shown in the illustration.

    3. A01ERJHE02

      Align the No. 2 chain yellow mark plates with the timing marks of the camshaft timing gear assembly and camshaft timing exhaust gear assembly, and attach the No. 2 chain to the gears as shown in the illustration.

      Note

      The camshaft timing exhaust gear has 2 grooves. Align the mark plates of the No. 2 chain with the first groove.

      Tech Tips

      The crankshaft timing sprocket RH and camshaft timing exhaust gear will be installed with the No. 1 and No. 2 chains connected to the gears.

    4. Install the crankshaft timing sprocket RH to the crankshaft.

    5. Align and attach the knock pin of the No. 1 camshaft with the pin hole of the camshaft timing gear.

    6. Using the hexagonal portion of the No. 2 camshaft, align and attach the knock pin of the No. 2 camshaft with the pin hole of the camshaft timing exhaust gear.

    7. Remove the pin from the No. 2 chain tensioner.

    8. Using a wrench to hold the hexagonal portion of the No. 1 camshaft, temporarily install the bolt.

    9. Using a wrench to hold the hexagonal portion of the No. 2 camshaft, temporarily install the bolt.

  9. INSTALL NO. 1 CHAIN VIBRATION DAMPER RH

    A01ESIK

    1. Install the vibration damper with the 2 bolts.

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

  10. INSTALL NO. 1 CHAIN TENSIONER SLIPPER RH

    A01ERPK

    Tech Tips

    If you cannot install the chain tensioner slipper due to the tension of the chain, use the hexagonal portion of the camshaft to loosen the chain, and then install the chain tensioner slipper.

  11. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY RH

    A01EP5SE02

    1. Move the stopper plate clockwise to release the lock, and push the plunger deep into the tensioner.

    2. Move the stopper plate counterclockwise to set the lock, and insert a hexagon wrench into the hole of the stopper plate.

    3. A01EN7X

      Install the chain tensioner with the 2 bolts.

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

    4. Remove the hexagon wrench from the chain tensioner.

  12. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY

    A01EQBIE04

    1. Install the chain tensioner with the 2 bolts.

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

    2. While pushing down the No. 2 chain tensioner, insert a pin of 1.0 mm (0.0394 in.) into the hole to fix it in place.

  13. INSTALL NO. 1 CHAIN SUB-ASSEMBLY LH

    A01EO99E01

    1. Align the No. 1 chain orange mark plate with the camshaft timing gear timing mark, and attach the chain to the gear as shown in the illustration.

    2. A01EPBHE03

      Align the No. 1 chain orange mark plate with the crankshaft timing sprocket timing mark, and attach the chain to the gear as shown in the illustration.

    3. A01ENOSE02

      Align the No. 2 chain yellow mark plates with the timing marks of the camshaft timing gear assembly and camshaft timing exhaust gear assembly, and attach the No. 2 chain to the gears as shown in the illustration.

      Note

      The camshaft timing exhaust gear has 2 grooves. Align the mark plates of the No. 2 chain with the first groove.

      Tech Tips

      The crankshaft timing sprocket LH and camshaft timing exhaust gear will be installed with the No. 1 and No. 2 chains connected to the gears.

    4. Install the crankshaft timing sprocket LH to the crankshaft.

    5. Align and attach the knock pin of the No. 3 camshaft with the pin hole of the camshaft timing gear.

    6. Using the hexagonal portion of the No. 4 camshaft, align and attach the knock pin of the No. 4 camshaft with the pin hole of the camshaft timing exhaust gear.

      Note

      Because the timing mark positions of the gears may shift due to looseness of the No. 1 chain, use the hexagonal portion of the camshaft to hold the No. 3 camshaft in place until the No. 1 chain tensioner is installed.

    7. Remove the pin from the No. 3 chain tensioner.

    8. Using a wrench to hold the hexagonal portion of the No. 3 camshaft, temporarily install the bolt.

    9. Using a wrench to hold the hexagonal portion of the No. 4 camshaft, temporarily install the bolt.

  14. INSTALL NO. 1 CHAIN TENSIONER SLIPPER LH

    A01EOT3

    Tech Tips

    If you cannot install the chain tensioner slipper due to the tension of the chain, use the hexagonal portion of the camshaft to loosen the chain, and install the chain tensioner slipper.

  15. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY LH

    A01EP5SE01

    1. Move the stopper plate clockwise to release the lock, and push the plunger deep into the tensioner.

    2. Move the stopper plate counterclockwise to set the lock, and insert a hexagon wrench into the hole of the stopper plate.

    3. A01EPGO

      Install a new gasket and the chain tensioner with the 2 bolts.

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

  16. INSTALL NO. 1 CHAIN VIBRATION DAMPER LH

    A01EP3K

    1. Install the vibration damper with the 2 bolts.

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

    2. Remove the hexagon wrench from the No. 1 chain tensioner.

  17. TIGHTEN CAMSHAFT TIMING GEAR ASSEMBLY


    1. A01EPIVE01

      for Bank 1:


      1. Using a wrench, hold the hexagonal portion of the No. 3 camshaft.

      2. Tighten the bolt of the camshaft timing gear.

        Torque:
        100 N*m  { 1020 kgf*cm, 74 ft.*lbf }
      3. A01ENPJE01

        Using a wrench to hold the hexagonal portion of the No. 4 camshaft, tighten the bolt of the camshaft timing exhaust gear.

        Torque:
        100 N*m  { 1020 kgf*cm, 74 ft.*lbf }
    2. A01ENBRE01

      for Bank 2:


      1. Using a wrench, hold the hexagonal portion of the No. 1 camshaft.

      2. Tighten the bolt of the camshaft timing gear.

        Torque:
        100 N*m  { 1020 kgf*cm, 74 ft.*lbf }
      3. A01ENCWE01

        Using a wrench to hold the hexagonal portion of the No. 2 camshaft, tighten the bolt of the camshaft timing exhaust gear.

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

  18. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily install the crankshaft pulley bolt.

    2. Rotate the crankshaft clockwise, and check that the timing marks on the crankshaft timing sprocket and camshaft timing gears are as shown in the illustration.

    3. Remove the crankshaft pulley bolt.

      A01ES9FE01

  19. INSTALL WATER INLET PIPE


    1. A01EPYT

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

    2. Install the inlet pipe to the No. 1 heat exchanger cover.

  20. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY


    1. A01EQ7O

      Apply a light coat of engine oil to a new oil pump gasket.

    2. Install the oil pump gasket.

    3. A01EP7J

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

    4. Install the O-ring.

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

      A01EPWUE01
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      • A01EPXOE02
        Apply Seal Packing as Follows
        Area Seal Packing Diameter Application Position from Inside Edge of Cover
        Continuous Line Area 3.0 to 4.0 mm (0.118 to 0.157 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 7.0 mm (0.276 in.)
        Diagonal Line Area 3.0 to 4.0 mm (0.118 to 0.157 in.) 5.5 mm (0.217 in.)

      Note


      • When the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.

      • Install the chain cover within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.

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

    6. A01EQYH

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

    7. A01EN80E01

      Temporarily install the timing chain cover with the 28 bolts and nut.

      Standard Bolt
      Item Length Thread Diameter
      Bolt A 25 mm (0.984 in.) 8 mm (0.315 in.)
      Bolt B 55 mm (2.17 in.) 8 mm (0.315 in.)
      Bolt C 70 mm (2.76 in.) 8 mm (0.315 in.)
      Bolt D 35 mm (1.38 in.) 10 mm (0.394 in.)
      Bolt E 55 mm (2.17 in.) 10 mm (0.394 in.)
      Bolt F 80 mm (3.15 in.) 10 mm (0.394 in.)

      Note

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

    8. A01ENITE01

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

      Torque:
      47 N*m  { 479 kgf*cm, 35 ft.*lbf }
    9. A01ES0CE01

      Temporarily install the fluid coupling bracket with the 4 bolts.

      Standard Bolt
      Item Length Thread Diameter
      Bolt A 70 mm (2.76 in.) 8 mm (0.315 in.)
      Bolt B 80 mm (3.15 in.) 10 mm (0.394 in.)
    10. A01ESLZ

      Temporarily install the belt tensioner with the standard bolt and 6 mm hexagon wrench bolt.

    11. A01ER1HE01

      Tighten the 8 bolts labeled 4 to 11 in several steps in the sequence shown in the illustration.

      Torque:
      47 N*m  { 479 kgf*cm, 35 ft.*lbf }
    12. A01ERY8E01

      Tighten the 23 bolts and nut labeled 12 to 35 in several steps in the sequence shown in the illustration.

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

      Note

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

      A01ESNEE01

  21. INSTALL SPARK PLUG TUBE GASKET

    A01ENJSE04

    1. Using a cutter knife, cut off the seal part of the removed gasket.

    2. A01ERIYE01

      Using the removed gasket and a hammer, tap in a new gasket until it stops.

      Tech Tips

      If the removed gasket does not fit on the new one, correct the removed one with pliers.

    3. Apply a light coat of MP grease to the lip of the gasket.

    4. Return the 4 ventilation baffle plate claws to the original positions.

  22. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH


    1. A01ENO4

      Install 5 new gaskets to the camshaft bearing caps (No. 2, No. 3).

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

      Note

      Remove any oil from the contact surface.

    3. A01ERX9E01

      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 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 the installation.

    4. A01ERR8E02

      Install the cylinder head cover and a new seal washer with the 14 bolts in the order shown in the illustration.

      Torque:
      for bolt A
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      except bolt A
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  23. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY RH


    1. A01ENCR

      Install 5 new gaskets to the camshaft bearing caps. (No. 1, No. 3).

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

      Note

      Remove any oil from the contact surface.

    3. A01ERL2E01

      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 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 the installation.

    4. A01EQUUE02

      Install the cylinder head cover and a new seal washer with the 14 bolts in the order shown in the illustration.

      Torque:
      for bolt A
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      except bolt A
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
    5. A01EOYL

      Install the noise filter to the cylinder head cover with the bolt.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

  24. INSTALL IGNITION COIL ASSEMBLY


    1. Install the 8 ignition coils with the 8 bolts.

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

  25. INSTALL CRANKSHAFT TIMING GEAR KEY


    1. A01EQ98

      Install the crankshaft timing gear key to the crankshaft.

  26. CONNECT WIRE HARNESS CLAMP BRACKET


    1. A01ENG0

      Connect the bracket to the timing chain cover with the bolt.

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

  27. INSTALL CRANKSHAFT PULLEY


    1. A01ERXIE02

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

    2. Using SST, install the pulley set bolt.

      SST
      09213-70011   ( 09213-70020 )
      09330-00021
      Torque:
      300 N*m  { 3059 kgf*cm, 221 ft.*lbf }

  28. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY


    1. A01EPW9

      Install the idler pulley with the bolt.

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

  29. INSTALL WATER PUMP PULLEY


    1. A01ENNRE01

      Temporarily install the pulley with the 4 bolts.

    2. Using SST, hold the pulley and tighten the 4 bolts.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )
      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  30. INSTALL WATER INLET HOUSING


    1. A01EPASE01

      Install a new gasket to the timing chain cover.

    2. A01EPWB

      Install the water inlet with the 3 bolts.

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

  31. INSTALL AIR PIPE SUB-ASSEMBLY (w/ Secondary Air Injection System)


    1. A01EQ6E

      Connect the 2 hoses.

    2. Install the air pipe with the bolt.

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

  32. INSTALL NO. 1 ENGINE COVER

    A01EOC2

    Tech Tips


    • Align the No. 1 engine cover cutouts with the air tube.

    • Align the No. 1 engine cover with the air switching valve surface and cylinder head wall.

    Note

    Make sure that the No. 1 engine cover is flush with the top surface of the intake port of the cylinder head for bank 1 and bank 2.

  33. INSTALL NO. 2 ENGINE COVER

    A01ES1W

    Tech Tips


    • Align the No. 2 engine cover cutout with the air tube.

    • Align the No. 2 engine cover with the front water by-pass joint and cylinder head wall.

    Note

    Make sure that the No. 2 engine cover is flush with the top surface of the intake port of the cylinder head.

  34. INSTALL FRONT WATER BY-PASS JOINT


    1. A01EPGZ

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

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

    2. Connect the No. 2 water by-pass hose to the water by-pass joint.

  35. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY


    1. Connect the 2 hoses.

    2. A01EPQI

      Install the water by-pass pipe with the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    3. A01EPL5

      w/ Secondary Air Injection System:

      Connect the air tube with the bolt.

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

  36. INSTALL NO. 1 WATER BY-PASS HOSE


    1. A01ESF9

      Install the No. 1 water by-pass hose by connecting the hose to the water inlet housing and front water by-pass joint.

  37. INSTALL GENERATOR ASSEMBLY


  38. CONNECT OIL COOLER PIPE ASSEMBLY


    1. A01EORU

      Connect the oil cooler pipe with the 2 bolts.

      Torque:
      14 N*m  { 143 kgf*cm, 10 ft.*lbf }

  39. INSTALL OIL FILTER ELEMENT


    1. A01ESHVE02

      Clean the inside of the oil filter cap, its threads and its O-ring groove.

    2. Apply a small amount of engine oil to a new O-ring and install it to the oil filter cap.

    3. Set a new oil filter element to the oil filter cap.

    4. Remove any dirt or foreign matter from the installation surface of the engine.

    5. Apply a small amount of engine oil to the O-ring again and temporarily install the oil filter cap.

      Note

      Do not remove the oil filter bracket clip.

    6. A01EQGPE02

      Using SST, tighten the oil filter cap.

      SST
      09228-06501
      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

      Note


      • When tightening the oil filter cap, do not remove the oil filter bracket clip.

      • Make sure that the oil filter is installed securely as shown in the illustration.

      • Be careful that the O-ring does not get caught between any surrounding parts.

    7. A01EQ01E01

      Apply a small amount of engine oil to a new drain plug O-ring, and install it to the oil filter cap.

      Note

      Before installing the O-ring, remove any dirt or foreign matter from the installation surface of the oil filter cap.

    8. Install the oil filter drain plug.

      Torque:
      13 N*m  { 127 kgf*cm, 9 ft.*lbf }

      Note

      Be careful that the O-ring does not get caught between any surrounding parts.

    9. A01EPCF

      Install the No. 2 engine under cover seal with the 2 bolts.

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

  40. CONNECT VANE PUMP ASSEMBLY

    Tech Tips

    A01EP6QE02

    Before performing the following procedures, move the spacer until the vane pump can be installed.


    1. A01ENCK

      Connect the vane pump to the timing chain cover with the 2 bolts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    2. A01ERYX

      Connect the 2 clamps and power steering oil pressure switch connector.

  41. INSTALL INTAKE MANIFOLD


    1. A01ERB8

      Place 2 new gaskets on the intake manifold.

    2. Place the intake manifold on the cylinder head.

    3. A01EN3R

      Install and uniformly tighten the 8 bolts and 2 nuts in several steps.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    4. A01EP15

      Install the wire bracket to the intake manifold with the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    5. A01EMUH

      Connect the 3 wire clamps to the 3 wire brackets.

    6. A01EQ2H

      Install the No. 3 engine cover.

    7. A01ER4I

      Install the No. 1 engine cover sub-assembly.

    8. A01EPU2

      Connect the purge VSV connector.

    9. Connect the purge line hose to the purge VSV.

    10. Connect the vacuum switching valve connector (for ACIS).

    11. A01EOVV

      Connect the No. 1 ventilation hose.

    12. A01ENH1

      Connect the 2 water by-pass hoses.

    13. Connect the throttle body connector.

    14. A01EPM5E01

      Connect the ventilation hose to the ventilation pipe of the cylinder head cover LH and RH.

  42. INSTALL OIL FILTER BRACKET (w/o Oil Cooler)


    1. A01EOY3

      Apply a light coat of engine oil to 2 new O-rings.

    2. Install the 2 O-rings to the timing chain cover.

    3. A01EREE

      Install the oil filter bracket with the 2 bolts and 2 nuts.

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

  43. INSTALL OIL FILTER BRACKET (w/ Oil Cooler)


    1. A01EOY3

      Apply a light coat of engine oil to 2 new O-rings.

    2. Install the 2 O-rings to the timing chain cover.

    3. A01EORI

      Install the oil filter bracket with the 2 nuts and 2 bolts.

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

  44. INSTALL NO. 1 OIL COOLER BRACKET (w/ Oil Cooler)


    1. A01ESNS

      Connect the ground wire to the cylinder block.

    2. Install the oil cooler bracket with the 2 nuts.

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

  45. INSTALL NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY (w/ Oil Cooler)


    1. Connect the 4 hoses.

    2. A01ERGG

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

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

  46. INSTALL OIL PRESSURE SENDER GAUGE ASSEMBLY


    1. A01ENPCE01

      Apply adhesive to 2 or 3 threads of the oil pressure sender gauge.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

      Note

      A01EN5AE01

      Do not allow adhesive to contact the oil hole.

    2. A01ERH7

      Install the oil pressure sender gauge.

      Torque:
      15 N*m  { 153 kgf*cm, 11 ft.*lbf }

      Note

      Do not start the engine within 1 hour after installation.

    3. A01EN3Y

      Connect the sender gauge connector.

  47. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE


    1. A01EPAO

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

    2. Install the O-ring to the guide.

    3. Install the dipstick guide with the bolt.

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

    4. Install the dipstick.

  48. CONNECT NO. 2 FUEL TUBE SUB-ASSEMBLY


    1. A01EPHOE01

      Connect the fuel tube with the 2 bolts.

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

  49. CONNECT COOLER COMPRESSOR ASSEMBLY


    1. A01ENT2E01

      Install the cooler compressor with the stud bolt.

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

    2. Install the 3 bolts and nut.

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

      Note

      Tighten the bolts and nut in the order shown in the illustration to install the cooler compressor.

  50. CONNECT NO. 2 WATER BY-PASS PIPE


    1. A01ENTS

      Connect the No. 2 water by-pass pipe to the cylinder head cover with the 3 bolts.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

    2. Connect the 3 hoses.

  51. CONNECT AIR PUMP HOSE AND WIRE HARNESS (w/ Secondary Air Injection System)


    1. A01EO09E01

      Connect the No. 2 and No. 3 air hoses.

    2. Connect the 2 clamps and air pump wire harness.

  52. CONNECT ENGINE WIRE


    1. A01EN06

      Engine Room RH Side:


      1. Connect the 5 clamps.

      2. Connect the throttle position sensor and throttle control motor connector.

      3. w/ Secondary Air Injection System:

        Connect the 2 air pump connectors.

      4. Install the ground wire with the 2 bolts.

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

      5. Connect the noise filter connector.

      6. Connect the 2 VVT sensor connectors.

        Tech Tips

        The wire harnesses on the exhaust side are wrapped with white tape.

      7. Connect the injector connector.

      8. Connect the 4 ignition coil connectors.

      9. Connect the 2 camshaft timing oil control valve connectors.

        Tech Tips

        The wire harnesses on the exhaust side are wrapped with white tape.

    2. A01EPDI

      Engine Room LH Side:


      1. Connect the cooler compressor connector.

      2. Connect the 3 clamps.

      3. Connect the camshaft position sensor connector.

      4. Connect the 2 camshaft timing oil control valve connectors.

        Tech Tips

        The wire harnesses on the exhaust side are wrapped with white tape.

      5. Connect the engine coolant temperature sensor connector.

      6. A01ENYA

        Connect the 4 clamps.

      7. Install the ground wire with the 2 bolts.

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

      8. Connect the noise filter connector.

      9. Connect the 2 VVT sensor connectors.

        Tech Tips

        The wire harnesses on the exhaust side are wrapped with white tape.

      10. Connect the 4 ignition coil connectors.

      11. Connect the injector connector.

      12. A01ERKB

        w/ Secondary Air Injection System:

        Connect the wire harness clamp and 4 air injection control driver connectors.

      13. A01EP9T

        Connect the 2 connectors and 2 clips to the engine room junction block.

      14. Install the engine room relay block cover.

  53. INSTALL RADIATOR ASSEMBLY


    1. A01EPEN

      Set the radiator bracket hooks to the radiator support holes.

    2. Install the radiator with the 4 bolts.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }
    3. A01EO0L

      Connect the 2 oil cooler hoses.

  54. INSTALL FAN SHROUD


    1. Install the fan pulley.

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

      Note

      Be careful not to damage the radiator core.

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

    4. A01ENP0E01

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

    5. Install the shroud with the 2 bolts.

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

    6. Connect the oil cooler tube to the fan shroud with the 2 bolts.

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

    7. w/ Air Cooled Transmission Oil Cooler:

      Pass the hose through the flexible hose clamp and close the clamp as shown in the illustration.

    8. Connect the reservoir hose to the upper radiator tank.

    9. Install the fan and generator V belt Click here.

    10. A01ESC5

      Tighten the 4 nuts of the fluid coupling fan.

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

  55. INSTALL NO. 2 RADIATOR HOSE

  56. INSTALL NO. 1 RADIATOR HOSE

  57. INSTALL AIR CLEANER ASSEMBLY


    1. A01ENV0

      Install the air cleaner with the 3 bolts.

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

  58. INSTALL AIR CLEANER HOSE ASSEMBLY


    1. A01EOSKE01

      Install the air cleaner hose so that the protrusion of the air cleaner cap aligns with the groove of the hose as shown in the illustration.

    2. Tighten the 2 clamps.

      Torque:
      2.5 N*m  { 25 kgf*cm, 22 in.*lbf }

    3. Connect the vacuum hose.

    4. Connect the No. 2 ventilation hose.

  59. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY


    1. A01EOFEE01

      Push in the ventilator louver to attach the 17 claws and install the ventilator louver.

    2. Install the 2 clips.

    3. A01EQS4

      Connect the washer hose.

  60. INSTALL HOOD TO COWL TOP SEAL


    1. A01EO3N

      Attach the 12 clips and 4 clamps to install the hood to cowl top seal.

  61. INSTALL FRONT FENDER MAIN SEAL LH


    1. A01ERY2

      Attach the 3 clips to install the fender main seal.

  62. INSTALL FRONT FENDER MAIN SEAL RH

    Tech Tips

    Use the same procedure described for the LH side.

  63. INSTALL FRONT WIPER ARM LH


    1. A01ENQ2E01

      Stop the wiper motor at the automatic stop position.

    2. Clean the wiper pivot serrations with a wire brush.

    3. A01ESC2E01

      Install the wiper arm and blade with the nut. Make sure that the wiper arm and blade come to the position shown in the illustration.

      Standard
      Position Specified Condition
      A 16.8 to 36.8 mm (0.661 to 1.45 in.)
      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

      Tech Tips

      Hold down the wiper arm hinge with your hand while tightening the nut.

  64. INSTALL FRONT WIPER ARM RH


    1. A01ENQ2E01

      Stop the wiper motor at the automatic stop position.

    2. Clean the wiper pivot serrations with a wire brush.

    3. A01ES7AE01

      Install the wiper arm and blade with the nut. Make sure that the wiper arm and blade come to the position shown in the illustration.

      Standard
      Position Specified Condition
      B 20.0 to 40.0 mm (0.787 to 1.57 in.)
      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

      Tech Tips

      Hold down the wiper arm hinge with your hand while tightening the nut.

    4. Operate the front wipers while spraying washer fluid on the windshield glass. Make sure that the front wipers function properly and there is no interference with the vehicle body.

  65. INSTALL RADIATOR SIDE DEFLECTOR LH


    1. A01EPV6

      Install the side deflector with the 5 clips.

  66. INSTALL RADIATOR SIDE DEFLECTOR RH (w/o Air Cooled Transmission Oil Cooler)


    1. A01EQ8A

      Install the side deflector with the 5 clips.

  67. INSTALL RADIATOR GRILLE


    1. w/ Wide View Front Monitor System:

      Connect the connector.

    2. Attach the 14 claws to install the radiator grille assembly.

    3. Attach the 4 clips to install the detached part of the upper radiator seal.

    4. Install the screw and 2 clips.

  68. ADD ENGINE OIL


    1. Add fresh oil and install the oil filler cap.

      Standard Oil Grade
      Oil Grade Oil Viscosity (SAE)

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

      API grade SL, SM or SN multigrade engine oil

      0W-20

      5W-20

      5W-30

      10W-30

      15W-40

      20W-50
      Standard Oil Capacity
      Item Specified Condition
      Drain and refill with oil filter change 7.5 liters (7.9 US qts, 6.6 Imp. qts)
      Drain and refill without oil filter change 7.1 liters (7.5 US qts, 6.2 Imp. qts)
      Dry fill 9.3 liters (9.8 US qts, 8.2 Imp. qts)

  69. ADD ENGINE COOLANT


    1. Add engine coolant.

      Standard Capacity
      Item Specified Condition
      with transmission oil cooler 16.7 liters (17.6 US qts, 14.7 Imp. qts)
      without transmission oil cooler 16.2 liters (17.1 US qts, 14.3 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 consists of a combination of low phosphates and organic acids).

    2. A01ERDWE01

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

    3. Install the reservoir cap.

    4. 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.

    5. Install the radiator cap.

    6. Start the engine and warm it up until the thermostat opens.

      Note

      Switch off the A/C.

    7. Maintain the engine speed at 2000 to 2500 rpm.

      Note


      • Make sure that the radiator reservoir still has some coolant in it.

      • Pay attention to the needle of the water temperature meter. 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.

      • 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.

      • Run the engine at 2000 rpm until the coolant level has stabilized.

    8. Press the No. 1 and No. 2 radiator hoses several times by hand to bleed air.

      CAUTION:


      • Wear protective gloves.

      • Be careful as the radiator hoses are hot.

      • Keep your hands away from the fan.

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

      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.

    10. A01EOUJE01

      Check that the coolant level is between the F and L lines.

      If the coolant level is below the L line, repeat all of the procedures above.

      If the coolant level is above the F line, drain coolant so that the coolant level is between the F and L lines.

  70. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  71. INSPECT FOR OIL LEAK


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

  72. INSPECT FOR COOLANT LEAK


    1. A01EPIJ

      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 123 kPa (1.3 kgf/cm2, 18 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.

  73. INSPECT ENGINE OIL LEVEL


    1. Warm up the engine. Then stop the engine and wait for 5 minutes.

    2. A01EOVLE01
      Text in Illustration
      *a Measuring Surface
      *b Low Level Mark
      *c Full Level Mark

      Check that the engine oil level is between the dipstick low level mark and full level mark.

      If the level is low, check for leakage and add oil up to the full level mark.

      Note

      Do not fill engine oil above the full level mark.

      Tech Tips

      A certain amount of engine oil will be consumed while driving. In the following situations, oil consumption may increase, and engine oil may need to be refilled in between oil maintenance intervals.


      • When the engine is new, for example directly after purchasing the vehicle or after replacing the engine.

      • If low quality oil or oil of an inappropriate viscosity is used.

      • When driving at high engine speed or with a heavy load, (when towing, or), when driving while accelerating or decelerating frequently.

      • When leaving the idling for a long time, or when driving frequently through heavy traffic.

      When judging the amount of oil consumption, keep in mind that the oil may have become diluted, making it difficult to judge the true level accurately.

  74. INSPECT IGNITION TIMING


    1. Warm up and stop the engine.


      1. Allow the engine to warm up to a normal operating temperature.

    2. Remove the engine room side cover LH.

    3. Remove the engine room side cover RH.

    4. Remove the upper radiator support seal.

    5. Remove the V-bank cover.

    6. When using the intelligent tester:


      1. Connect the intelligent tester to the DLC3.

      2. Start the engine and idle it.

      3. Turn the intelligent tester ON.

      4. Enter the following menus: Powertrain / Engine and ECT / Data List / Primary / IGN Advance.

        Tech Tips

        Refer to the intelligent tester operator's manual for further details.

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

      5. Disconnect the intelligent tester from the DLC3.

    7. A01EN0B

      When not using the intelligent tester:


      1. 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.

      2. A01ER02E01

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

        SST
        09843-18040

        Note


        • Confirm the terminal numbers before connecting them. Connecting the wrong terminals can damage the engine.

        • Switch off all accessories and the A/C before connecting the terminals.

      3. A01ENW5

        Using the timing light, check the ignition timing.

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

      4. Remove SST from the DLC3.

      5. Check the ignition timing.

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

      6. Disconnect the timing light from the engine.

    8. Install the V-bank cover.

    9. Install the upper radiator support seal.

    10. Install the engine room side cover RH.

    11. Install the engine room side cover LH.

  75. INSPECT ENGINE IDLE SPEED


    1. Warm up and stop the engine.


      1. Allow the engine to warm up to a normal operating temperature.

    2. When using the intelligent tester:


      1. Connect the intelligent tester to the DLC3.

        Note

        Switch off all accessories and the A/C before connecting the intelligent tester.

      2. Race the engine at 2500 rpm for approximately 90 seconds.

      3. Turn the intelligent tester ON.

      4. Enter the following menus: Powertrain / Engine and ECT / Data List / Primary / Engine Speed.

        Standard idle speed
        650 to 750 rpm (transmission in neutral and A/C switch off)

        Tech Tips

        Refer to the intelligent tester operator's manual for further details.

        If the idle speed is not as specified, check the air intake system.

      5. Disconnect the intelligent tester from the DLC3.

    3. A01ER02E02

      When not using the intelligent tester:


      1. Using SST, connect the tachometer probe to terminal 9 (TAC) of the DLC3.

        SST
        09843-18030

        Note


        • Confirm the terminal number before connecting the probe. Connecting the probe to the wrong terminal can damage the engine.

        • Switch off all accessories and the A/C before connecting the probe.

      2. Race the engine at 2500 rpm for approximately 90 seconds.

      3. Check the idle speed.

        Standard idle speed
        650 to 750 rpm (transmission in neutral and A/C switch off)

        If the idle speed is not as specified, check the air intake system.

      4. Disconnect the tachometer probe from the DLC3.

  76. INSTALL FRONT FENDER APRON SEAL FRONT RH


    1. A01EO1I

      Install the fender apron seal with the 3 clips.

  77. INSTALL FRONT FENDER APRON SEAL FRONT LH


    1. A01EPDR

      Install the fender apron seal with the 4 clips.

  78. INSTALL NO. 2 ENGINE UNDER COVER


    1. A01ERKF

      Install the No. 2 engine under cover with the 2 bolts.

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

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


    1. A01EN7K

      Install the No. 1 engine under cover with the 10 bolts.

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

  80. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH


    1. Push in the clip to install the front fender splash shield sub-assembly LH.

    2. Install the 3 bolts and 2 screws.

  81. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH

    Tech Tips

    Use the same procedure described for the LH side.

  82. INSTALL V-BANK COVER SUB-ASSEMBLY


    1. A01EPLGE01

      Attach the 2 V-bank cover hooks to the bracket. Then align the 3 V-bank cover grommets with the 3 pins, and press down on the V-bank cover to attach the pins.

  83. INSTALL UPPER RADIATOR SUPPORT SEAL


    1. Install the upper radiator support seal with the 3 clips.

  84. INSTALL ENGINE ROOM SIDE COVER RH


    1. Install the engine room side cover RH with the 7 clips.

  85. INSTALL ENGINE ROOM SIDE COVER LH


    1. Install the engine room side cover LH with the 7 clips.