PROCEDURE
INSTALL WATER INLET PIPE
Apply soapy water to 2 new O-rings and install them to the water inlet pipe.
Install the water 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 gasket.
Install the gasket to the cylinder block.
Apply a light coat of engine oil to a new O-ring.
Install the O-ring to the oil pan.
Apply seal packing in a continuous line to the timing chain cover as shown in the following illustration.
*1 | Continuous Line Area | *2 | Dashed Line Area |
*3 | Diagonal Line Area | - | - |
*a | 20.0 mm (0.787 in.) | *b | 26.0 mm (1.02 in.) |
*c | 16.0 mm (0.630 in.) | *d | 18.0 mm (0.709 in.) |
*e | 7.0 mm (0.276 in.) | - | - |
Seal packing |
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Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent |
Application Specification | ||||||||||||
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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.
Align the oil pump drive rotor spline and crankshaft as shown in the illustration and install the chain cover.
*1 | Nut |
Temporarily install the 26 bolts and nut.
Standard Bolt | |||||||||||||||||||||
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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 fan bracket with the 5 bolts.
Standard Bolt | |||||||||
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Bolt A | |
Bolt B |
Temporarily install the belt tensioner with the bolt and 6 mm hexagon bolt.
Bolt | |
6 mm Hexagon Bolt |
Tighten the 8 bolts labeled 4 to 11 in several steps in the sequence shown in the illustration.
Tighten the 22 bolts and nut labeled 12 to 34 in several steps in the sequence shown in the illustration.
Note
Do not start the engine for at least 2 hours after the installation.
After the installation, if the seal packing has seeped out at the areas labeled A shown in the illustration, wipe it off.
Labeled A |
Check the torque of each bolt and nut again.
INSTALL FRONT CRANKSHAFT OIL SEAL
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH
Install 5 new gaskets to the camshaft bearing caps (No. 2, No. 3).
Install a new cylinder head cover gasket LH to the cylinder head cover sub-assembly LH.
Note
Remove any oil from the contact surface.
Apply seal packing as shown in the illustration.
Seal packing |
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Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent |
Seal Packing |
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.
Install a new seal washer to the bolt.
Temporarily install the cylinder head cover sub-assembly LH with the 14 bolts. Tighten the bolts uniformly in several steps.
Standard Bolt | |||||||||
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Bolt A | |
Bolt B |
Note
Do not start the engine for at least 2 hours after the installation.
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY RH
Install 5 new gaskets to the camshaft bearing caps. (No. 1, No. 3).
Install a new cylinder head cover gasket RH to the cylinder head cover sub-assembly RH.
Note
Remove any oil from the contact surface.
Apply seal packing as shown in the illustration.
Seal packing |
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Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent |
Seal Packing |
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.
Install a new seal washer to the bolt.
Temporarily install the cylinder head cover sub-assembly RH with the 14 bolts. Tighten the bolts uniformly in several steps.
Standard Bolt | |||||||||
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Bolt A | |
Bolt B |
Note
Do not start the engine for at least 2 hours after the installation.
INSTALL IGNITION COIL ASSEMBLY
INSTALL CRANKSHAFT PULLEY
Align the key groove of the pulley with the pulley set key, and slide on the pulley to install it.
*a | Hold |
Turn |
Using SST, install the pulley set bolt.
INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY
Install the No. 1 idler pulley with the bolt.
INSTALL WATER PUMP PULLEY
INSTALL FRONT WATER BY-PASS JOINT
Install 2 new gaskets and the water by-pass joint with the 4 nuts.
INSTALL WATER INLET HOUSING
INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY
Install the water by-pass pipe sub-assembly with the 2 bolts.
Connect the No. 2 water by-pass hose from the front water by-pass joint.
CONNECT NO. 5 WATER BY-PASS HOSE
INSTALL NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY
INSTALL NO. 1 WATER BY-PASS HOSE
CONNECT WATER BY-PASS HOSE
INSTALL NO. 1 WATER BY-PASS PIPE
Connect the No. 1 water by-pass pipe with the 2 bolts.
Connect the heater water hose.
INSTALL NO. 3 AIR TUBE (w/ Secondary Air Injection System)
Install a new gasket to the No. 3 air tube.
*1 | No. 3 Air Tube |
*2 | Claw |
*3 | Exhaust Manifold |
Install the No. 3 air tube with the 2 stud bolts, 2 nuts and bolt.
Note
Make sure the claws of the gasket are not caught between the No. 3 air tube and exhaust manifold.
INSTALL NO. 4 AIR TUBE (w/ Secondary Air Injection System)
Install a new gasket to the No. 4 air tube.
*1 | No. 4 Air Tube |
*2 | Claw |
*3 | Exhaust Manifold |
Install the No. 4 air tube with the 2 stud bolts, 2 nuts and bolt.
Note
Make sure the claws of the gasket are not caught between the No. 4 air tube and exhaust manifold.
Install the wire harness clamp bracket with the bolt.
INSTALL FUEL HOSE
Install the fuel hose Click here.
Install the fuel pipe clamp.
Connect the 2 clamps.
INSTALL FUEL TUBE SUB-ASSEMBLY
Install the fuel tube Click here.
Install the 2 bolts.
INSTALL NO. 3 ENGINE COVER
INSTALL NO. 4 ENGINE COVER
INSTALL GENERATOR ASSEMBLY
CONNECT OIL COOLER TUBE
CONNECT VANE PUMP ASSEMBLY
Tech Tips
Before performing the following procedures, move the spacer until the vane pump can be installed.
Spacer |
Connect the vane pump to the timing chain cover with the 2 bolts.
CONNECT POWER STEERING OIL PRESSURE SWITCH CONNECTOR
INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE
INSTALL OIL FILTER BRACKET
INSTALL NO. 1 OIL COOLER BRACKET
INSTALL OIL PRESSURE SENDER GAUGE ASSEMBLY
INSTALL OIL FILTER ELEMENT
CONNECT ENGINE WIRE
Connect the clamp and engine wire with the bolt.
for Engine Room RH Side:
Connect the 6 clamps.
Connect the noise filter connector.
Connect the injector connector.
Connect the 2 VVT sensor connectors.
Connect the 4 ignition coil connectors.
Connect the 2 camshaft timing oil control valve connectors.
for Engine Room LH Side:
Install the ground wire with the bolt.
Connect the 8 clamps.
Connect the noise filter connector.
Connect the engine coolant temperature sensor connector.
Connect the camshaft position sensor connector.
Connect the 2 VVT sensor connectors.
Connect the 4 ignition coil connectors.
Connect the 2 camshaft timing oil control valve connectors.
Connect the injector connector.
INSTALL AIR TUBE (w/ Secondary Air Injection System)
Install the air tube with the 2 bolts.
Connect the No. 3 air injection system hose.
Attach the wire harness clamp.
INSTALL AIR SWITCHING VALVE ASSEMBLY (w/ Secondary Air Injection System)
for Bank 1 Click here
for Bank 2 Click here
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.
INSTALL INTAKE MANIFOLD
INSTALL RADIATOR ASSEMBLY
INSTALL AIR CLEANER AND HOSE
INSTALL FRONT FENDER APRON TRIM PACKING A
ADD ENGINE OIL
ADD ENGINE COOLANT
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 ENGINE OIL LEVEL
INSPECT FOR OIL LEAK
INSPECT FOR COOLANT LEAK
INSTALL V-BANK COVER SUB-ASSEMBLY