Oil Pump Installation

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.

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

1. Apply Seal Packing as Follows:

   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	Seal Packing Thickness
   *4	Seal Packing Width
   *5	OK Area

NOTICE:

1. When the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.
   
2. 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. Install the spline and chain cover to the crankshaft.

Temporarily install the timing chain cover with the 28 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 fluid coupling bracket with the 4 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.)

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.

Torque:

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

Tighten the 23 bolts and nut labeled 12 to 35 in several steps in the sequence shown in the illustration.

Torque:

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

NOTICE:

1. Do not start the engine for at least 2 hours after installing.
   


2. After the installation, if the seal packing has seeped out at the areas labeled A shown in the illustration, wipe it off.
   

Using a cutter knife, cut off the seal part of the removed gasket.

Text in Illustration

Area to cut off

Using the removed gasket and a hammer, tap in a new gasket until it stops.

HINT:

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 5 new gaskets to the camshaft bearing caps (No. 2, No. 3).

Install a new gasket to the cylinder head cover.

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:

1. Remove any oil from the contact surface.
   
2. Install the cylinder head cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
   

Install the cylinder head cover and a new seal washer with the 14 bolts in the order shown in the illustration.

Torque:

for bolt A:

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

except bolt A:

12 N*m{122 kgf*cm, 9 ft.*lbf}

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 gasket to the cylinder head cover.

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:

1. Remove any oil from the contact surface.
   
2. Install the cylinder head cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
   

Install the cylinder head cover and a new seal washer with the 14 bolts in the order shown in the illustration.

Torque:

for bolt A:

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

except bolt A:

12 N*m{122 kgf*cm, 9 ft.*lbf}

NOTICE:

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

Install the noise filter to the cylinder head cover with the bolt.

Torque:

7.0 N*m{71 kgf*cm, 62 in.*lbf}

Install the 8 ignition coils with the 8 bolts.

Torque:

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

Install the crankshaft timing gear key to the crankshaft.

Connect the bracket to the timing chain cover with the bolt.

Torque:

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

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

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 idler pulley with the bolt.

Torque:

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

Temporarily install the pulley with the 4 bolts.

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

SST

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

Torque:

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

Install a new gasket to the timing chain cover.

Install the water inlet with the 3 bolts.

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}

Connect the No. 2 water by-pass hose to the water by-pass joint.

Connect the 2 hoses.

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

Torque:

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

Install the No. 1 water by-pass hose by connecting the hose to the water inlet housing and front water by-pass joint.

Install the stud bolt.

Torque:

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

Install the generator assembly with the 3 bolts and nut.

Torque:

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

Connect the harness bracket to the generator assembly 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 pipe 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}

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.

Torque:

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

Install the wire bracket to the intake manifold with the bolt.

Torque:

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

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.

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}

Connect the 4 hoses.

Install the water by-pass pipe with the 3 bolts.

Torque:

10 N*m{102 kgf*cm, 7 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 allow adhesive to contact the oil hole.

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 sender gauge connector.

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.

Torque:

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

Install the dipstick.

Connect the wire harness clamp.

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.

NOTICE:

Do not remove the oil filter bracket clip.

Using SST, tighten the oil filter cap.

SST

09228-06501

Torque:

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

NOTICE:

1. When tightening the oil filter cap, do not remove the oil filter bracket clip.
   
2. Make sure that the oil filter is installed securely as shown in the illustration.
   
3. 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.

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.

Install the No. 2 engine under cover seal with the 2 bolts.

Torque:

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

Connect the fuel tube with the 2 bolts.

Torque:

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

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.

Connect the water pipe and hose to the cylinder head cover with the 2 bolts.

Torque:

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

Connect the 3 hoses.

Connect the 2 clamps and power steering oil pressure switch connector.

Engine Room RH Side:

1. Connect the 6 clamps.
   

2. Connect the throttle position sensor and throttle control motor connector.
   

3. Connect the ground wire with the bolt.
   

   Torque:

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

4. Connect the noise filter connector.
   

5. Connect the 2 VVT sensor connectors.
   

6. Connect the injector connector.
   

7. Connect the 4 ignition coil connectors.
   

8. Connect the 2 camshaft timing oil control valve connectors.
   

Engine Room LH Side:

1. Connect the cooler compressor connector.
   

2. Connect the 3 clamps.
   

3. Connect the camshaft position sensor connector.
   

4. Connect the 2 camshaft timing oil control valve connectors.
   

5. Connect the engine coolant temperature sensor connector.
   

6. Connect the 4 clamps.
   

7. Connect the ground wire with the bolt.
   

   Torque:

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

8. Connect the noise filter connector.
   

9. Connect the 2 VVT sensor connectors.
   

10. Connect the 4 ignition coil connectors.
    

11. Connect the injector connector.
    

12. Connect the 2 connectors and 2 clips to the engine room junction block.
    

13. Install the engine room relay block cover.
    

Install the air cleaner with the 3 bolts.

Torque:

5.0 N*m{51 kgf*cm, 44 in.*lbf}

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.

Torque:

2.5 N*m{25 kgf*cm, 22 in.*lbf}

Connect the vacuum hose.

Connect the No. 2 ventilation hose.

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 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	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:

Item	Specified Condition
with rear heater	16.2 liters (17.1 US qts, 14.3 Imp. qts)
without rear heater	13.4 liters (14.2 US qts, 11.8 Imp. qts)

NOTICE:

Do not substitute plain water for engine coolant.

HINT:

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.

HINT:

The thermostat opening timing can be confirmed by pressing the radiator inlet hose by hand, and checking when the engine coolant starts to flow inside the hose.

Maintain the engine speed at 2000 to 2500 rpm.

NOTICE:

1. Make sure that the radiator reservoir still has some coolant in it.
   
2. Pay attention to the needle of the water temperature meter. Make sure that the needle does not show an abnormally high temperature.
   
3. If there is not enough coolant, the engine may burn out or overheat.
   
4. 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.
   
5. 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:

1. Wear protective gloves.
   
2. Be careful as the radiator hoses are hot.
   
3. 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.

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

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.

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.

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.

1. When the engine is new, for example directly after purchasing the vehicle or after replacing the engine.
   
2. If low quality oil or oil of an inappropriate viscosity is used.
   
3. When driving at high engine speed or with a heavy load, (when towing, or), when driving while accelerating or decelerating frequently.
   
4. 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 the No. 2 engine under cover with the 2 bolts.

Torque:

29 N*m{296 kgf*cm, 21 ft.*lbf}

Install the No. 1 engine under cover with the 10 bolts.

Torque:

29 N*m{296 kgf*cm, 21 ft.*lbf}

Install the fender apron seal with the 3 clips.

Install the fender apron seal with the 3 clips.

Install the radiator side deflector LH with the 4 clips.

Install the transmission oil cooler air duct with the 4 bolts.

Torque:

4.9 N*m{50 kgf*cm, 43 in.*lbf}