PROCEDURE
INSTALL TIMING CHAIN COVER ASSEMBLY
Install a new gasket to the cylinder head sub-assembly.
Apply a light coat of engine oil to a new No. 2 oil strainer gasket and a new oil pump gasket.
Install the No. 2 oil strainer gasket and oil pump gasket to the stiffening crankcase assembly.
*1 | Crankshaft Timing Sprocket |
*a | Drive Rotor Spline |
Align the positions of the drive rotor spline and crankshaft timing sprocket as shown in the illustration.
Apply seal packing to the timing chain cover assembly at the points shown in the illustration.
*a | 28 mm (1.10 in.) | *b | 25 mm (0.984 in.) |
*c | 26 mm (1.02 in.) | *d | 2.5 mm (0.0984 in.) |
*e | 2.5 to 3.0 mm (0.0984 to 0.118 in.) | *f | 7.0 mm (0.276 in.) or more |
*g | 5.0 mm (0.197 in.) | *h | 13 mm (0.512 in.) or more |
*i | 7.0 mm (0.276 in.) | *j | 3.0 mm (0.118 in.) or more |
Seal Packing |
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Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent. |
Seal Packing Application Specification | |||||||||||||||||||||||||||||||||||
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Note
Clean the surfaces with non-residue solvent before applying seal packing.
Install the timing chain cover sub-assembly within 3 minutes and tighten the bolts within 10 minutes of applying seal packing.
Do not add oil for at least 2 hours after installation.
Do not start the engine for at least 2 hours after installation.
Temporarily install the timing chain cover assembly with the 3 nuts and 19 bolts.
*a | Torque | *b | Tightening Order |
Bolt | Nut |
Bolt Length | |||||||||
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Note
Do not apply oil to the bolts. If oil is applied to the bolts, clean it off.
When tightening the 15th bolt shown in the illustration, be careful not to damage the installation surface of the crankshaft position sensor.
Tighten the 19 bolts and 3 nuts in several steps, in the order shown in the illustration.
INSTALL TIMING CHAIN COVER OIL SEAL
INSTALL CRANKSHAFT POSITION SENSOR
INSTALL CRANKSHAFT PULLEY ASSEMBLY
INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
INSTALL IDLER PULLEY SUB-ASSEMBLY
INSTALL CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY
INSTALL WATER OUTLET SUB-ASSEMBLY
INSTALL AIR CLEANER BRACKET
INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE
INSTALL NO. 6 WATER BY-PASS HOSE
*a | Upper Side |
*b | Front Side |
*c | LH Side |
*d | 45° |
*e | Paint Mark |
Connect the No. 6 water by-pass hose with the 2 clips as shown in the illustration.
Tech Tips
Install the clips so that they are positioned as shown in the illustration.
INSTALL CYLINDER HEAD COVER GASKET
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
CONNECT NO. 3 VENTILATION HOSE
INSTALL NO. 1 TURBO WATER PIPE
CONNECT ENGINE WIRE
for Engine Upper Side:
Connect the engine wire to the cylinder head cover sub-assembly with the bolt.
Engage the clamp and connect the No. 3 ventilation hose to the engine wire.
Connect the air fuel ratio sensor connector.
for Engine Front Side:
Connect the engine wire to the timing chain cover assembly with the bolt and 3 nuts.
Engage the clamp and connect the 5 connectors.
for Engine LH Side:
Engage the clamp and connect the connector.
Connect the connector with the 2 bolts.
Engage the claw to connect the connector holder to the engine room ECU box.
Connect the engine wire with the nut.
Push down the lock lever to connect the ECM connector.
Note
When connecting a connector, make sure that dirt, water and other foreign matter is not stuck between the connector and ECM.
Make sure that the lever is securely lowered.
Connect the 4 connectors.
INSTALL ENGINE ROOM ECU COVER
CONNECT SUCTION HOSE
Remove the vinyl tape from the suction hose.
Sufficiently apply compressor oil to a new O-ring and the fitting surface of the suction hose.
Install the O-ring to the suction hose.
Note
Keep the O-ring and O-ring fitting surface free of foreign matter.
Connect the suction hose to the suction pipe sub-assembly with the nut.
INSTALL IGNITION COIL ASSEMBLY
INSTALL NO. 4 VENTILATION HOSE
INSTALL VENTILATION HOSE
INSTALL FUEL PUMP ASSEMBLY (for High Pressure)
INSTALL COMPRESSOR AND MAGNETIC CLUTCH
INSTALL RADIATOR ASSEMBLY