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CAMSHAFT OIL CONTROL VALVE INSTALLATION

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  1. Click here

    INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY


    1. A019KC6E07

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

      Table 1. Text in Illustration
      *1 O-ring
    2. A019KU2E02

      Install the 4 oil control valves with the 4 bolts.

      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. A019OAR

      Install the bolt and connect the wire harness clamp to install the engine wire.

      14 N*m 138 kgf*cm 10 ft.*lbf
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    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. A019MTQ

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

      Bolt
      18 N*m 184 kgf*cm 13 ft.*lbf
      Nut
      16 N*m 163 kgf*cm 12 ft.*lbf
    3. A019NBS

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

      21 N*m 214 kgf*cm 15 ft.*lbf
    4. A019KEL

      Connect the connector to the intake air control valve assembly.

    5. A019M0E

      Connect the ventilation hose and vacuum hose.

    6. A019MBG

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

    7. A019N1A

      Connect the vacuum hose clamp and fuel vapor feed hose.

    8. A019JMB

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

    9. A019KAPE01

      Connect the union to check valve hose.

      Table 2. Text in Illustration
      *1 for RHD:
      *2 for LHD:
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    INSTALL AIR CLEANER ASSEMBLY


    1. A019M7QE01

      Insert the tab of the air cleaner assembly to the hole of the vehicle body as shown in the illustration.

      Table 3. Text in Illustration
      *1 Tab
      *2 Hole
    2. A019JQO

      Install the air cleaner assembly with the 2 bolts.

      5.5 N*m 56 kgf*cm 49 in.*lbf
    3. A019L8LE01

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

      Table 4. Text in Illustration
      *1 Ventilation Hose
      *2 Fuel Vapor Feed Hose

    4. Connect the ventilation hose and the fuel vapor feed hose.

    5. A019LU3

      Connect the 2 vacuum hoses.

    6. A019KSB

      Connect the 2 wire harness clamps and vacuum switching valve connector.

    7. A019LPG

      Connect the vacuum hose to the intake air surge tank assembly.

    8. Install the hose to the hose clamp.

    9. A019K7G

      Connect the mass air flow meter connector and wire harness clamp.

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    INSTALL NO. 1 AIR CLEANER INLET


    1. A019ND6

      Install the No. 1 air cleaner inlet with the bolt.

      8.0 N*m 82 kgf*cm 71 in.*lbf

    2. Connect the vacuum hose clamp to the No. 1 air cleaner inlet.

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    INSTALL NO. 2 AIR CLEANER INLET


    1. A019O60

      Install the No. 2 air cleaner inlet with the 2 bolts.

      8.0 N*m 82 kgf*cm 71 in.*lbf

    2. Connect the 2 vacuum hose clamps to the No. 2 air cleaner inlet.

  6. Click here

    INSTALL BATTERY


    1. Install the battery and battery tray.

    2. A019LTJ

      Install the battery clamp with the bolt and nut.

      5.4 N*m 55 kgf*cm 48 in.*lbf

    3. Connect the positive (+) cable to the positive (+) battery terminal.

      6.4 N*m 65 kgf*cm 57 in.*lbf
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    CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note:

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

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    ADD ENGINE COOLANT


    1. Tighten the radiator drain cock plug by hand.

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

      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)

      13 N*m 130 kgf*cm 9 ft.*lbf

    4. Loosen the air drain cock plug on the water inlet housing.

    5. Add engine coolant to the radiator inlet opening until engine coolant overflows from the air drain cock hole. Then tighten the air drain cock plug to the water inlet housing.

      13 N*m 130 kgf*cm 9 ft.*lbf

    6. Slowly fill the radiator assembly with engine coolant.

      Standard capacity
      9.5 liters (10.0 US qts, 8.3 Imp. qts)
      Note:

      Do not substitute plain water for engine coolant.

      Tip:

      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).

    7. Remove the reserve tank cap.

    8. A019MVWE03

      Slowly pour engine coolant into the radiator reserve tank assembly until it reaches the full line.

      Table 5. Text in Illustration
      *a Full Line

    9. 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.

    10. Install the radiator cap sub-assembly and reserve tank cap.

    11. Bleed air from the cooling system.

      Note:

      • Before starting the engine, turn the A/C switch off.

      • Adjust the heater control to the maximum hot setting.

      • Adjust the blower speed to the low setting.


      1. Warm up the engine until the thermostat opens. While the thermostat is open, circulate the engine coolant for several minutes.

        Tip:

        The thermostat open timing can be confirmed by squeezing the No. 2 radiator hose by hand, and sensing vibrations when the engine coolant starts to flow inside the No. 2 radiator hose.

      2. Maintain the engine speed at 2500 to 3000 rpm.

      3. Squeeze the No. 1 radiator hose and No. 2 radiator hose several times by hand to bleed air.

        CAUTION:

        When squeezing the No. 1 radiator hose and No. 2 radiator hose:


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

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

        • If the radiator reserve tank assembly does not have enough engine coolant, the engine may overheat or be seriously damaged.

        • If the radiator reserve tank assembly does not have enough engine coolant, perform the following: 1) stop the engine, 2) wait until the engine coolant has cooled down, and 3) add engine coolant until the radiator reserve tank assembly is filled to the full line.

    12. Stop the engine, and wait until the engine coolant cools down.

    13. Add engine coolant to the full line on the radiator reserve tank assembly.

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    INSPECT FOR ENGINE COOLANT LEAK

    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.

    Note:

    Before performing each inspection, turn the A/C switch off.


    1. Remove the radiator cap.

    2. A019MDJ

      Fill the radiator with coolant and attach a radiator cap tester.

    3. Warm up the engine.

    4. Using the radiator cap tester, increase the pressure inside the radiator to 118 kPa (1.2 kgf/cm2, 17 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 cylinder head.

    5. Remove the radiator cap tester.

    6. Install the radiator cap.

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    INSPECT FOR OIL LEAK


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

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    INSTALL V-BANK COVER SUB-ASSEMBLY


    1. A019LVN

      Fit the 4 retainers and install the V-bank cover sub-assembly.

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    INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY (for LHD)


    1. A019OCLE01

      Install the outer cowl top panel sub-assembly with the 4 bolts, 4 nuts*1 and 2 nuts*2.

      Nut*1
      85 N*m 867 kgf*cm 63 ft.*lbf
      Nut*2
      5.5 N*m 56 kgf*cm 49 in.*lbf
      Bolt
      5.5 N*m 56 kgf*cm 49 in.*lbf
    2. A019O7N

      Engage the grommet and clamp to install the wire harness.

    3. Connect the connector (w/ Windshield Deicer).

  13. Click here

    INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY (for RHD)


    1. A019OF3E01

      Install the outer cowl top panel sub-assembly with the 4 bolts, 4 nuts*1 and 2 nuts*2.

      Nut*1
      85 N*m 867 kgf*cm 63 ft.*lbf
      Nut*2
      5.5 N*m 56 kgf*cm 49 in.*lbf
      Bolt
      5.5 N*m 56 kgf*cm 49 in.*lbf
    2. A019N0P

      Engage the grommet and clamp to install the wire harness.

    3. Connect the connector (w/ Windshield Deicer).

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    INSTALL FRONT SHOCK ABSORBER CAP (w/ Air Suspension)


    1. A019N7O

      Install the front shock absorber cap with the 3 nuts.

      14 N*m 143 kgf*cm 10 ft.*lbf
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    INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY


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

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    INSTALL NO. 1 ENGINE UNDER COVER