Installation
1UR-FE LUBRICATION: OIL PUMP: INSTALLATION
1. INSTALL WATER INLET PIPE
(a) Apply soapy water to 2 new O-rings and install them to the inlet pipe.
(b) Install the inlet pipe to the No. 1 heat exchanger cover.
2. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY
(a) Apply a light coat of engine oil to a new gasket.
(b) Install the gasket to the cylinder block.
(c) Apply a light coat of engine oil to a new O-ring.
(d) Install the O-ring to the oil pan.
(e) Apply seal packing in a continuous line to the timing chain cover as shown in the following illustration.
Text in Illustration
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
*
Application Specification:
Text in Illustration
NOTICE:
* 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.
(f) Align the oil pump drive rotor spline and crankshaft as shown in the illustration and install the chain cover.
(g) Temporarily install the 26 bolts and nut.
Standard Bolt:
NOTICE:
Make sure that there is no oil on the bolt threads.
(h) Tighten the 3 bolts in several steps in the sequence shown in the illustration.
Torque : 47 Nm (479 kgf-cm, 35 ft-lbf)
(i) Temporarily install the fan bracket with the 5 bolts.
Standard Bolt:
Text in Illustration
(j) Temporarily install the belt tensioner with the bolt and 6 mm hexagon bolt.
Text in Illustration
(k) Tighten the 8 bolts labeled 4 to 11 in several steps in the sequence shown in the illustration.
Torque : 47 Nm (479 kgf-cm, 35 ft-lbf)
(l) Tighten the 22 bolts and nut labeled 12 to 34 in several steps in the sequence shown in the illustration.
Torque : 23 Nm (235 kgf-cm, 17 ft-lbf)
NOTICE:
Do not start the engine for at least 2 hours after the installation.
NOTICE:
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
(m) Check the torque of each bolt and nut again.
3. INSTALL FRONT CRANKSHAFT OIL SEAL Installation
4. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH
(a) Install 5 new gaskets to the camshaft bearing caps (No. 2, No. 3).
(b) Install the cover gasket to the cylinder head cover.
NOTICE:
Remove any oil from the contact surface.
(c) Apply seal packing as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Text in Illustration
NOTICE:
* 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.
(d) Install a new seal washer to the bolt.
(e) Temporarily install the cylinder head cover with the 14 bolts. Tighten the bolts uniformly in several steps.
for bolt A - Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
for bolt B - Torque : 12 Nm (122 kgf-cm, 9 ft-lbf)
Standard Bolt:
Text in Illustration
NOTICE:
Do not start the engine for at least 2 hours after the installation.
5. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY RH
(a) Install 5 new gaskets to the camshaft bearing caps. (No. 1, No. 3).
(b) Install the cover gasket to the cylinder head cover.
NOTICE:
Remove any oil from the contact surface.
(c) Apply seal packing as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Text in Illustration
NOTICE:
* 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.
(d) Install a new seal washer to the bolt.
(e) Temporarily install the cylinder head cover with the 14 bolts. Tighten the bolts uniformly in several steps.
for bolt A - Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
for bolt B - Torque : 12 Nm (122 kgf-cm, 9 ft-lbf)
Standard Bolt:
Text in Illustration
NOTICE:
Do not start the engine for at least 2 hours after the installation.
6. INSTALL IGNITION COIL ASSEMBLY Installation
7. INSTALL NO. 3 AIR TUBE
(a) Install a new gasket to the No. 3 air tube.
(b) Install the No. 3 air tube with the 2 stud bolts, 2 nuts and bolt.
for bolt and nut - Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
for stud bolt - Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)
Text in Illustration
NOTICE:
Make sure the claws of the gasket are not caught between the No. 3 air tube and exhaust manifold.
(c) Install the 2 wire harness clamp brackets with the 2 bolts.
Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)
8. INSTALL NO. 4 AIR TUBE
(a) Install a new gasket to the No. 4 air tube.
(b) Install the No. 4 air tube with the 2 stud bolts, 2 nuts and bolt.
for bolt and nut - Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
for stud bolt - Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)
Text in Illustration
NOTICE:
Make sure the claws of the gasket are not caught between the No. 4 air tube and exhaust manifold.
(c) Install the 2 wire harness clamp brackets with the 2 bolts.
Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)
9. INSTALL CRANKSHAFT PULLEY
(a) Align the key groove of the pulley with the pulley set key, and slide on the pulley to install it.
(b) Using SST, install the pulley set bolt.
SST : 09213-70011
SST : 09330-00021
Torque : 300 Nm (3059 kgf-cm, 221 ft-lbf)
Text in Illustration
10. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY
(a) Install the idler pulley with the bolt.
Torque : 43 Nm (438 kgf-cm, 32 ft-lbf)
11. INSTALL WATER PUMP PULLEY Installation
12. INSTALL FRONT WATER BY-PASS JOINT
(a) Install 2 new gaskets and the water by-pass joint with the 4 nuts.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
13. INSTALL WATER INLET HOUSING
(a) Install a new gasket to the timing chain cover.
(b) Install the water inlet housing with the 3 bolts.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
14. CONNECT NO. 5 WATER BY-PASS HOSE Installation
15. CONNECT NO. 8 WATER BY-PASS HOSE Installation
16. INSTALL NO. 3 WATER BY-PASS HOSE
(a) Install the hose.
Text in Illustration
HINT
Align the paint mark on the hose with the protrusion of the front water by-pass joint, and then align the claw of the clip with the paint mark.
17. INSTALL NO. 3 WATER BY-PASS PIPE
(a) Connect the hose.
(b) Install the water by-pass pipe with the 2 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
Text in Illustration
HINT
The direction of the hose clamp is indicated in the illustration.
18. INSTALL NO. 1 WATER BY-PASS HOSE Installation
19. INSTALL WATER BY-PASS HOSE
(a) Install the water by-pass hose.
Text in Illustration
HINT
Be sure to align the claw of the clip with the paint mark on the hose.
20. CONNECT NO. 4 WATER BY-PASS PIPE
(a) Connect the No. 4 water by-pass pipe with the 2 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
21. CONNECT HEATER WATER HOSE
(a) Connect the 2 heater water hoses.
Text in Illustration
HINT
The direction of the hose clamp is indicated in the illustration.
22. INSTALL FUEL HOSE
(a) Install the fuel hose with the clamp Service Precautions.
(b) Install the EFI fuel pipe clamp.
23. INSTALL FUEL TUBE SUB-ASSEMBLY
(a) Install the fuel tube with the 2 bolts Service Precautions.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(b) Install the EFI fuel pipe clamp.
24. INSTALL NO. 3 ENGINE COVER Installation
25. INSTALL NO. 4 ENGINE COVER Installation
26. INSTALL GENERATOR ASSEMBLY Installation
27. CONNECT VANE PUMP ASSEMBLY
HINT
Before performing the following procedures, move the spacer until the vane pump can be installed.
Text in Illustration
(a) Connect the vane pump to the timing chain cover with the 2 bolts.
Torque : 43 Nm (438 kgf-cm, 32 ft-lbf)
28. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE Installation
29. INSTALL OIL FILTER BRACKET SUB-ASSEMBLY
(a) Apply a light coat of engine oil to 2 new O-rings.
(b) Install the 2 O-rings to the timing chain cover.
(c) Install the oil filter bracket with the 2 nuts and 2 bolts.
Torque : 35 Nm (357 kgf-cm, 26 ft-lbf)
Standard Bolt:
Text in Illustration
30. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY Installation
31. INSTALL OIL FILTER ELEMENT Replacement
32. CONNECT ENGINE WIRE
(a) Connect the clamp and engine wire with the bolt.
Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)
(b) for Engine Room RH Side:
(1) Connect the wire harness clamp bracket with the bolt.
Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)
(2) Connect the wire harness clamp.
(3) Connect the 6 clamps.
(4) Install the ground wire with the bolt.
Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)
(5) Connect the noise filter connector.
(6) Connect the 2 VVT sensor connectors.
(7) Connect the injector connector.
(8) Connect the 4 ignition coil connectors.
Connect the 2 camshaft timing oil control valve connectors.
Connect the power steering oil pressure switch connector and solenoid valve connector.
(c) for Engine Room LH Side:
(1) Connect the cooler compressor connector.
(2) Connect the 6 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 noise filter connector.
(7) Connect the 2 VVT sensor connectors.
(8) Connect the 4 ignition coil connectors.
Connect the injector connector.
33. INSTALL AIR SWITCHING VALVE ASSEMBLY (for Bank 2) Installation
34. INSTALL AIR SWITCHING VALVE ASSEMBLY (for Bank 1) Installation
35. INSTALL AIR TUBE SUB-ASSEMBLY Installation
36. INSTALL FRONT FENDER APRON SEAL RH Installation
37. INSTALL AIR CLEANER CASE SUB-ASSEMBLY Installation
38. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY
39. INSTALL AIR CLEANER CAP AND HOSE Installation
40. INSTALL COOLER COMPRESSOR ASSEMBLY
(a) Install the cooler compressor Installation.
41. INSTALL INTAKE MANIFOLD
(a) Install the intake manifold Installation.
42. INSTALL RADIATOR ASSEMBLY
(a) Install the radiator Installation.
43. ADD ENGINE OIL Replacement
44. ADD ENGINE COOLANT Service and Repair
45. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected Repair Instruction - Initialization.
46. INSPECT FOR OIL LEAK Replacement
47. INSPECT FOR COOLANT LEAK Testing and Inspection
48. CHECK ENGINE OIL LEVEL Testing and Inspection