INSTALL WATER INLET PIPE
Apply soapy water to 2 new O-rings and install them to the inlet pipe.
Install the inlet pipe to the No. 1 heat exchanger cover.
INSTALL TIMING CHAIN COVER SUB-ASSEMBLY
Apply a light coat of engine oil to a new oil pump gasket.
Install the oil pump gasket.
Apply a light coat of engine oil to a new O-ring.
Install the O-ring.
Apply seal packing in a continuous line to the timing chain cover as shown in the following illustration.
| Seal packing |
|---|
| Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent |
| Apply Seal Packing as Follows | ||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|
|
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.
Align the oil pump drive rotor spline and crankshaft as shown in the illustration. Install the spline and chain cover to the crankshaft.
Temporarily install the timing chain cover with the 28 bolts and nut.
| Standard Bolt | |||||||||||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
|
Note
Make sure that there is no oil on the bolt threads.
Tighten the 3 bolts in several steps in the sequence shown in the illustration.
Temporarily install the fluid coupling bracket with the 4 bolts.
| Standard Bolt | |||||||||
|---|---|---|---|---|---|---|---|---|---|
|
Temporarily install the belt tensioner with the standard bolt and 6 mm hexagon wrench bolt.
Tighten the 8 bolts labeled 4 to 11 in several steps in the sequence shown in the illustration.
Tighten the 23 bolts and nut labeled 12 to 35 in several steps in the sequence shown in the illustration.
Note
After the installation, if the seal packing has seeped out at the areas labeled A shown in the illustration, wipe it off.
INSTALL SPARK PLUG TUBE GASKET
Using a cutter knife, cut off the seal part of the removed gasket.
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.
Apply a light coat of MP grease to the lip of the gasket.
Return the 4 ventilation baffle plate claws to the original positions.
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH
Install 5 new gaskets to the camshaft bearing caps (No. 2, No. 3).
Install a new gasket to the cylinder head cover.
Note
Remove any oil from the contact surface.
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.
Install the cylinder head cover and a new seal washer with the 14 bolts in the order shown in the illustration.
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY RH
Install 5 new gaskets to the camshaft bearing caps. (No. 1, No. 3).
Install a new gasket to the cylinder head cover.
Note
Remove any oil from the contact surface.
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.
Install the cylinder head cover and a new seal washer with the 14 bolts in the order shown in the illustration.
Install the noise filter to the cylinder head cover with the bolt.
INSTALL IGNITION COIL ASSEMBLY
Install the 8 ignition coils with the 8 bolts.
INSTALL CRANKSHAFT TIMING GEAR KEY
Install the crankshaft timing gear key to the crankshaft.
CONNECT WIRE HARNESS CLAMP BRACKET
Connect the bracket to the timing chain cover with the bolt.
INSTALL CRANKSHAFT PULLEY
Align the pulley set key with the key groove of the pulley, and slide on the pulley.
Using SST, install the pulley set bolt.
INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY
Install the idler pulley with the bolt.
INSTALL WATER PUMP PULLEY
Temporarily install the pulley with the 4 bolts.
Using SST, hold the pulley and tighten the 4 bolts.
INSTALL WATER INLET HOUSING
Install a new gasket to the timing chain cover.
Install the water inlet with the 3 bolts.
INSTALL AIR PIPE SUB-ASSEMBLY (w/ Secondary Air Injection System)
Connect the 2 hoses.
Install the air pipe with the bolt.
INSTALL NO. 1 ENGINE COVER
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.
INSTALL NO. 2 ENGINE COVER
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.
INSTALL FRONT WATER BY-PASS JOINT
Install 2 new gaskets and the water by-pass joint with the 4 nuts.
Connect the No. 2 water by-pass hose to the water by-pass joint.
INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY
Connect the 2 hoses.
Install the water by-pass pipe with the 2 bolts.
w/ Secondary Air Injection System:
Connect the air tube with the bolt.
INSTALL NO. 1 WATER BY-PASS HOSE
Install the No. 1 water by-pass hose by connecting the hose to the water inlet housing and front water by-pass joint.
INSTALL GENERATOR ASSEMBLY
for 150A Type:
for 180A Type:
CONNECT OIL COOLER PIPE ASSEMBLY
Connect the oil cooler pipe with the 2 bolts.
CONNECT VANE PUMP ASSEMBLY
Tech Tips
Before performing the following procedures, move the spacer until the vane pump can be installed.
Connect the vane pump to the timing chain cover with the 2 bolts.
Connect the 2 clamps and power steering oil pressure switch connector.
INSTALL INTAKE MANIFOLD
Place 2 new gaskets on the intake manifold.
Place the intake manifold on the cylinder head.
Install and uniformly tighten the 8 bolts and 2 nuts in several steps.
Install the wire bracket to the intake manifold with the bolt.
Connect the 3 wire clamps to the 3 wire brackets.
Install the No. 3 engine cover.
Install the No. 1 engine cover sub-assembly.
Connect the purge VSV connector.
Connect the purge line hose to the purge VSV.
Connect the vacuum switching valve connector (for ACIS).
Connect the No. 1 ventilation hose.
Connect the 2 water by-pass hoses.
Connect the throttle body connector.
Connect the ventilation hose to the ventilation pipe of the cylinder head cover LH and RH.
INSTALL OIL FILTER BRACKET (w/o Oil Cooler)
Apply a light coat of engine oil to 2 new O-rings.
Install the 2 O-rings to the timing chain cover.
Install the oil filter bracket with the 2 bolts and 2 nuts.
INSTALL OIL FILTER BRACKET (w/ Oil Cooler)
Apply a light coat of engine oil to 2 new O-rings.
Install the 2 O-rings to the timing chain cover.
Install the oil filter bracket with the 2 nuts and 2 bolts.
INSTALL NO. 1 OIL COOLER BRACKET (w/ Oil Cooler)
Connect the ground wire to the cylinder block.
Install the oil cooler bracket with the 2 nuts.
INSTALL NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY (w/ Oil Cooler)
Connect the 4 hoses.
Install the water by-pass pipe with the 3 bolts.
INSTALL OIL PRESSURE SENDER GAUGE ASSEMBLY
Apply adhesive to 2 or 3 threads of the oil pressure sender gauge.
| Adhesive |
|---|
| Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent |
Note
Do not allow adhesive to contact the oil hole.
Install the oil pressure sender gauge.
Note
Do not start the engine within 1 hour after installation.
Connect the sender gauge connector.
INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE
Apply a light coat of engine oil to a new O-ring.
Install the O-ring to the guide.
Install the dipstick guide with the bolt.
Install the dipstick.
INSTALL OIL FILTER ELEMENT
Clean the inside of the oil filter cap, its threads and its O-ring groove.
Apply a small amount of engine oil to a new O-ring and install it to the oil filter cap.
Set a new oil filter element to the oil filter cap.
Remove any dirt or foreign matter from the installation surface of the engine.
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.
Using SST, tighten the oil filter cap.
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.
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.
Install the oil filter drain plug.
Note
Be careful that the O-ring does not get caught between any surrounding parts.
Install the No. 2 engine under cover seal with the 2 bolts.
CONNECT NO. 2 FUEL TUBE SUB-ASSEMBLY
Connect the fuel tube with the 2 bolts.
CONNECT COOLER COMPRESSOR ASSEMBLY
Install the cooler compressor with the stud bolt.
Install the 3 bolts and nut.
Note
Tighten the bolts and nut in the order shown in the illustration to install the cooler compressor.
CONNECT NO. 2 WATER BY-PASS PIPE
Connect the No. 2 water by-pass pipe to the cylinder head cover with the 3 bolts.
Connect the 3 hoses.
CONNECT AIR PUMP HOSE AND WIRE HARNESS (w/ Secondary Air Injection System)
Connect the No. 2 and No. 3 air hoses.
Connect the 2 clamps and air pump wire harness.
CONNECT ENGINE WIRE
Engine Room RH Side:
Connect the 5 clamps.
Connect the throttle position sensor and throttle control motor connector.
w/ Secondary Air Injection System:
Connect the 2 air pump connectors.
Install the ground wire with the 2 bolts.
Connect the noise filter connector.
Connect the 2 VVT sensor connectors.
Tech Tips
The wire harnesses on the exhaust side are wrapped with white tape.
Connect the injector connector.
Connect the 4 ignition coil connectors.
Connect the 2 camshaft timing oil control valve connectors.
Tech Tips
The wire harnesses on the exhaust side are wrapped with white tape.
Engine Room LH Side:
Connect the cooler compressor connector.
Connect the 3 clamps.
Connect the camshaft position sensor connector.
Connect the 2 camshaft timing oil control valve connectors.
Tech Tips
The wire harnesses on the exhaust side are wrapped with white tape.
Connect the engine coolant temperature sensor connector.
Connect the 4 clamps.
Install the ground wire with the 2 bolts.
Connect the noise filter connector.
Connect the 2 VVT sensor connectors.
Tech Tips
The wire harnesses on the exhaust side are wrapped with white tape.
Connect the 4 ignition coil connectors.
Connect the injector connector.
w/ Secondary Air Injection System:
Connect the wire harness clamp and 4 air injection control driver connectors.
Connect the 2 connectors and 2 clips to the engine room junction block.
Install the engine room relay block cover.
INSTALL RADIATOR ASSEMBLY
INSTALL AIR CLEANER ASSEMBLY
Install the air cleaner with the 3 bolts.
INSTALL AIR CLEANER HOSE ASSEMBLY
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.
Tighten the 2 clamps.
Connect the vacuum hose.
Connect the No. 2 ventilation hose.
INSTALL V-BANK COVER SUB-ASSEMBLY
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.
ADD ENGINE OIL
Add fresh oil and install the oil filler cap.
| Standard Oil Grade | ||||
|---|---|---|---|---|
|
| Standard Oil Capacity | ||||||||
|---|---|---|---|---|---|---|---|---|
|
ADD ENGINE COOLANT
Add engine coolant.
| Standard Capacity | ||||||
|---|---|---|---|---|---|---|
|
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).
Slowly pour coolant into the radiator reservoir until it reaches the F line.
Install the reservoir cap.
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.
Install the radiator cap.
Start the engine and warm it up until the thermostat opens.
Note
Switch off the A/C.
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.
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.
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.
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.
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Note
When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.
INSPECT FOR OIL LEAK
Start the engine. Make sure that there are no oil leaks from the area that was worked on.
INSPECT FOR COOLANT LEAK
Fill the radiator with coolant and attach a radiator cap tester.
Warm up the engine.
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.
INSPECT ENGINE OIL LEVEL
Warm up the engine. Then stop the engine and wait for 5 minutes.
| *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.
INSTALL NO. 2 ENGINE UNDER COVER
Install the No. 2 engine under cover with the 2 bolts.
INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY
Install the No. 1 engine under cover with the 10 bolts.
INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH
Push in the clip to install the front fender splash shield sub-assembly LH.
Install the 3 bolts and 2 screws.
INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH
Tech Tips
Use the same procedure described for the LH side.
INSTALL FRONT FENDER APRON SEAL FRONT RH
Install the fender apron seal with the 3 clips.
INSTALL FRONT FENDER APRON SEAL FRONT LH
Install the fender apron seal with the 4 clips.
INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY
CONNECT RADIATOR SIDE DEFLECTOR LH
Install the side deflector with the 5 clips.
CONNECT RADIATOR SIDE DEFLECTOR RH (w/o Air Cooled Transmission Oil Cooler)
Install the side deflector with the 5 clips.
INSTALL RADIATOR GRILLE
w/ Wide View Front Monitor System:
Connect the connector.
Attach the 14 claws to install the radiator grille assembly.
Attach the 4 clips to install the detached part of the upper radiator seal.
Install the screw and 2 clips.
INSTALL UPPER RADIATOR SUPPORT SEAL
Install the upper radiator support seal with the 3 clips.
INSTALL ENGINE ROOM SIDE COVER RH
Install the engine room side cover RH with the 7 clips.
INSTALL ENGINE ROOM SIDE COVER LH
Install the engine room side cover LH with the 7 clips.