INSTALL WATER INLET PIPE

INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

INSTALL FRONT CRANKSHAFT OIL SEAL

INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH

INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY RH

INSTALL IGNITION COIL ASSEMBLY

INSTALL CRANKSHAFT PULLEY

INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY

INSTALL WATER PUMP PULLEY

INSTALL FRONT WATER BY-PASS JOINT

INSTALL WATER INLET HOUSING

INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY

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

INSTALL NO. 3 AIR TUBE (w/ Secondary Air Injection System)

INSTALL NO. 4 AIR TUBE (w/ Secondary Air Injection System)

INSTALL FUEL HOSE

INSTALL FUEL TUBE SUB-ASSEMBLY

INSTALL NO. 3 ENGINE COVER

INSTALL NO. 4 ENGINE COVER

INSTALL GENERATOR ASSEMBLY

CONNECT OIL COOLER TUBE

CONNECT VANE PUMP ASSEMBLY

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

INSTALL AIR TUBE (w/ Secondary Air Injection System)

INSTALL AIR SWITCHING VALVE ASSEMBLY (w/ Secondary Air Injection System)

CONNECT COOLER COMPRESSOR ASSEMBLY

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

INSPECT ENGINE OIL LEVEL

INSPECT FOR OIL LEAK

INSPECT FOR COOLANT LEAK

INSTALL V-BANK COVER SUB-ASSEMBLY

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.

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.

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

• Application Specification:

• 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.)

Text in Illustration

*1	Seal Packing Thickness mm (in.)
*2	Seal Packing Width mm (in.)
*3	Thickness
*4	Width
	OK Area

• NOTICE:

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

Temporarily install the 26 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.)

• NOTICE:

• 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.

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

Temporarily install the fan bracket with the 5 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.)

Text in Illustration

	Bolt A
	Bolt B

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

Text in Illustration

	Bolt
	6 mm Hexagon Bolt

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}

Tighten the 22 bolts and nut labeled 12 to 34 in several steps in the sequence shown in the illustration.

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

• NOTICE:

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.

Text in Illustration

Labeled A

Check the torque of each bolt and nut again.

Apply MP grease to the lip of a new front crankshaft oil seal.

• NOTICE:

Using SST and a hammer, tap in the front crankshaft oil seal to a depth between 0 and 1.0 mm (0 to 0.0394 in.) from the timing chain cover edge.

• SST
• 09223-22010
  09506-35010

• NOTICE:

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.

• NOTICE:

• 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

Text in Illustration

Seal Packing

• NOTICE:

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.

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

• Standard Bolt:

• Item	Length	Thread Diameter
  Bolt A	70 mm (2.76 in.)	8 mm (0.315 in.)
  Bolt B	25 mm (0.984 in.)	6 mm (0.236 in.)

Text in Illustration

	Bolt A
	Bolt B

• NOTICE:

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

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.

• NOTICE:

• 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

Text in Illustration

Seal Packing

• NOTICE:

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.

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

• Standard Bolt:

• Item	Length	Thread Diameter
  Bolt A	70 mm (2.76 in.)	8 mm (0.315 in.)
  Bolt B	25 mm (0.984 in.)	6 mm (0.236 in.)

Text in Illustration

	Bolt A
	Bolt B

• NOTICE:

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

for Bank 2:

for Bank 1:

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

Using SST, install the pulley set bolt.

• SST
• 09213-70011
  09330-00021

• Torque:
• 300 N*m{ 3059 kgf*cm, 221 ft.*lbf}

Text in Illustration

*a	Hold
	Turn

Install the No. 1 idler pulley with the bolt.

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

Temporarily install the water pump pulley with the 4 bolts.

Using SST, hold the water pump pulley and tighten the 4 bolts.

• SST
• 09960-10010(09962-01000,09963-01000)

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

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

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

Install a new gasket to the engine water pump.

Install the water inlet housing with the 3 bolts.

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

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

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

Connect the No. 2 water by-pass hose from the front water by-pass joint.

Connect the 4 hoses.

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

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

Connect the No. 1 water by-pass pipe with the 2 bolts.

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

Connect the heater water hose.

Install a new gasket to the No. 3 air tube.

Install the No. 3 air tube with the 2 stud bolts, 2 nuts and bolt.

• Torque:
• for bolt and nut:
• 10 N*m{ 102 kgf*cm, 7 ft.*lbf}
• for stud bolt:
• 5.0 N*m{ 51 kgf*cm, 44 in.*lbf}

• NOTICE:

• Make sure the claws of the gasket are not caught between the No. 3 air tube and exhaust manifold.

Install a new gasket to the No. 4 air tube.

Install the No. 4 air tube with the 2 stud bolts, 2 nuts and bolt.

• Torque:
• for bolt and nut:
• 10 N*m{ 102 kgf*cm, 7 ft.*lbf}
• for stud bolt:
• 5.0 N*m{ 51 kgf*cm, 44 in.*lbf}

• NOTICE:

• 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.

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

Install the fuel hose ().

Install the fuel pipe clamp.

Connect the 2 clamps.

Install the fuel tube ().

Install the 2 bolts.

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

Install the No. 3 engine cover.

Text in Illustration

Engine Front

• HINT:

• Position the No. 3 engine cover so that the arrow mark faces the front of the engine and install it.

Install the No. 4 engine cover.

Text in Illustration

Engine Front

• HINT:

• Position the No. 4 engine cover so that the arrow mark faces the front of the engine and install it.

Install the stud bolt.

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

Install the generator with the 3 bolts and nut.

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

Connect the harness bracket to the generator with the bolt.

• Torque:
• 31 N*m{ 316 kgf*cm, 23 ft.*lbf}

Connect the generator wire with the nut.

• Torque:
• 9.8 N*m{ 100 kgf*cm, 87 in.*lbf}

Close the terminal cap.

Connect the generator connector.

Connect the oil cooler tube with the 2 bolts.

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

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

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

Apply engine oil to a new O-ring, and then install the O-ring to the engine oil level dipstick guide.

Install the engine oil level dipstick guide with the bolt.

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

Attach the engine wire clamp.

Install the engine oil level dipstick.

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.

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

Connect the ground wire to the cylinder block.

Install the oil cooler bracket with the 2 nuts.

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

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

• Adhesive:
• Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

• NOTICE:

• Do not apply adhesive to the oil inlet port of the oil pressure sender gauge.

Install the oil pressure sender gauge.

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

• NOTICE:

• Do not start the engine within 1 hour after installation.

Connect the oil pressure sender gauge connector.

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

Apply a light coat of engine oil to a new O-ring for the cap, and then install the O-ring to the groove of the oil filter cap.

• NOTICE:

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.

• NOTICE:

Using SST, tighten the oil filter cap.

• SST
• 09228-06501

• Torque:
• 25 N*m{ 255 kgf*cm, 18 ft.*lbf}

• NOTICE:

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

• NOTICE:

• 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.

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

• NOTICE:

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

Connect the clamp and engine wire with the bolt.

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

for Engine Room RH Side:

for Engine Room LH Side:

Install the air tube with the 2 bolts.

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

Connect the No. 3 air injection system hose.

Attach the wire harness clamp.

Install the cooler compressor with the stud bolt.

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

Install the 3 bolts and nut.

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

• NOTICE:

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

Install the air cleaner and hose with the 3 bolts, and then tighten the hose clamp.

• Torque:
• for bolt:
• 5.0 N*m{ 51 kgf*cm, 44 in.*lbf}
• for hose clamp:
• 2.5 N*m{ 25 kgf*cm, 22 in.*lbf}

Attach the clamp and connect the mass air flow meter connector.

Connect the No. 2 PCV hose and No. 1 air hose.

Install the front fender apron trim packing A with the 3 clips.

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	0W-20 5W-20 5W-30 10W-30
  API grade SL, SM or SN multigrade engine oil	15W-40 20W-50

• Standard Oil Capacity:

• Item	Specified Condition
  Drain and refill without oil filter change	7.1 liters (7.5 US qts, 6.2 Imp. qts)
  Drain and refill with oil filter change	7.5 liters (7.9 US qts, 6.6 Imp. qts)
  Dry fill	9.3 liters (9.8 US qts, 8.2 Imp. qts)

Add engine coolant.

• Standard Capacity (w/o ATF Warmer):

• Item	Specified Condition
  w/ Rear Heater	16.5 liters (17.4 US qts, 14.5 Imp. qts)
  w/o Rear Heater	13.8 liters (14.6 US qts, 12.1 Imp. qts)

• Standard Capacity (w/ ATF Warmer):

• Item	Specified Condition
  w/ Rear Heater	17.0 liters (18.0 US qts, 15.0 Imp. qts)
  w/o Rear Heater	14.2 liters (15.0 US qts, 12.5 Imp. qts)

• NOTICE:

• Do not substitute plain water for engine coolant.

• HINT:

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

Install the reservoir cap.

Install the radiator cap.*1

Start the engine and stop it immediately.*2

Allow approximately 10 seconds to pass. Then remove the radiator cap and check the coolant level. If the coolant level has decreased, add coolant.*3

Repeat steps *1, *2 and *3 until the coolant level does not decrease.

• HINT:

• Be sure to perform this step while the engine is cold, as air in the No. 1 radiator hose will flow into the radiator if the engine is warmed up and the thermostat opens.

Install the radiator cap.*4

Set the air conditioning as follows.*5

Start the engine, warm it up until the thermostat opens, and then continue to run the engine for several minutes to circulate the coolant.*6

• CAUTION:

• NOTICE:

• HINT:

Stop the engine, wait until the engine coolant cools down to ambient temperature. Then remove the radiator cap and check the coolant level.*7

• 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.

If the coolant level has decreased, add coolant and warm up the engine until the thermostat opens.*8

If the coolant level has not decreased, check that the coolant level in the radiator reservoir is at the F line.

If the coolant level is below the F line, repeat steps *4 through *8.

If the coolant level is above the F line, drain coolant until the coolant level reaches the F line.

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

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.

• NOTICE:

• Do not fill engine oil above the full level mark.

• HINT:

• 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 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.

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

Remove the radiator cap.

Check for excessive deposits of rust or scales around the radiator reservoir cap and radiator reservoir filler hole. Also, the engine coolant should be free of oil.

If excessively dirty, replace the engine coolant.

Install the radiator cap.

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.