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 oil pump gasket.
(b) Install the oil pump gasket.
(c) Apply a light coat of engine oil to a new O-ring.
(d) Install the O-ring.
(e) 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
Apply Seal Packing As Follows:
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.
* Do not start the engine for at least 2 hours after installing.
(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:
(j) Temporarily install the belt tensioner with the bolt and 6 mm hexagon bolt.
(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 23 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:
After the installation, if the seal packing has seeped out at the areas labeled A shown in the illustration, wipe it off.
3. INSTALL FRONT CRANKSHAFT OIL SEAL Reassembly
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
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 the cylinder head cover and a new seal washer with the 14 bolts.
for bolt A - Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
except bolt A - Torque : 12 Nm (122 kgf-cm, 9 ft-lbf)
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
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 the cylinder head cover and a new seal washer with the 14 bolts.
for bolt A - Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
except bolt A - Torque : 12 Nm (122 kgf-cm, 9 ft-lbf)
NOTICE:
Do not start the engine for at least 2 hours after the installation.
6. INSTALL IGNITION COIL ASSEMBLY
(a) Install the 8 ignition coils with the 8 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
7. CONNECT NO. 3 AIR TUBE
(a) Install a new gasket to the No. 3 air tube.
Connect the No. 3 air tube with the 2 nuts and bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
NOTICE:
Make sure the gasket's claws are not caught between the No. 3 air tube and exhaust manifold.
Install the wire harness clamp bracket with the bolt.
Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)
8. CONNECT NO. 4 AIR TUBE
(a) Install a new gasket to the No. 4 air tube.
Connect the No. 4 air tube with the 2 nuts and bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
NOTICE:
Make sure the gasket's claws are not caught between the No. 4 air tube and exhaust manifold.
Install the wire harness clamp bracket with the bolt.
Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)
9. INSTALL CRANKSHAFT PULLEY
Align the key groove of the pulley with the pulley set key, and slide on the pulley to install it.
(a) Using SST, install the pulley set bolt.
SST : 09213-70011
SST : 09330-00021
Torque : 300 Nm (3059 kgf-cm, 221 ft-lbf)
10. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY
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
Install 2 new gaskets and the water by-pass joint with the 4 nuts.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
(a) Install the No. 2 water by-pass hose to the water by-pass joint.
13. INSTALL WATER INLET HOUSING
Install a new gasket to the timing chain cover.
(a) 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 WATER BY-PASS PIPE SUB-ASSEMBLY
Connect the hose.
(a) Install the water by-pass pipe with the 2 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
17. INSTALL AIR TUBE SUB-ASSEMBLY RH
Install the air tube with the 2 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
18. INSTALL NO. 1 WATER BY-PASS HOSE Installation
19. INSTALL NO. 3 ENGINE COVER Installation
20. INSTALL NO. 4 ENGINE COVER Installation
21. INSTALL GENERATOR ASSEMBLY Installation
22. CONNECT OIL COOLER TUBE SUB-ASSEMBLY (w/ Trailer Towing System) Installation
23. CONNECT VANE PUMP ASSEMBLY
HINT
Before performing the following procedures, move the spacer until the vane pump can be installed.
Connect the vane pump to the timing chain cover with the 2 bolts.
Torque : 28 Nm (286 kgf-cm, 21 ft-lbf)
24. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE Installation
25. INSTALL OIL FILTER BRACKET Installation
26. INSTALL NO. 1 OIL COOLER BRACKET (w/ Oil Cooler) Installation
27. INSTALL WATER BY-PASS PIPE (w/ Oil Cooler)
Connect the 4 hoses.
(a) Install the water by-pass pipe with the 2 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
28. INSTALL OIL PRESSURE SENDER GAUGE ASSEMBLY Installation
29. INSTALL OIL FILTER ELEMENT Replacement
30. CONNECT COOLER COMPRESSOR ASSEMBLY
Connect the cooler compressor with the 2 stud bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(a) Install the 2 bolts and 2 nuts.
Torque : 25 Nm (250 kgf-cm, 18 ft-lbf)
NOTICE:
Tighten the bolts and nuts in the order shown in the illustration to connect the cooler compressor.
31. CONNECT HEATER HOSE AND NO. 1 WATER BY-PASS PIPE
Connect the No. 1 water by-pass pipe with the 2 bolts.
Torque : 18 Nm (184 kgf-cm, 13 ft-lbf)
(a) Connect the heater hose.
32. CONNECT NO. 3 AIR INJECTION SYSTEM HOSE
Connect the No. 3 air injection system hose.
33. CONNECT ENGINE WIRE
Connect the bracket to the timing chain cover with the bolt.
Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)
(a) Engine Room RH Side:
(1) Connect the 9 clamps.
(2) Connect the 2 air pump connectors.
(3) Install the ground wire with the bolt.
Torque : 8.0 Nm (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.
(9) Connect the power steering oil pressure switch connector and solenoid valve connector.
(10) for 4WD:
Connect the clamp and junction connector.
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) Install the ground wire with the bolt.
Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)
(7) Connect the noise filter connector.
(8) Connect the 2 VVT sensor connectors.
(9) Connect the 4 ignition coil connectors.
(10) Connect the injector connector.
Connect the 2 wire harness clamps.
Connect the 4 air injection control driver connectors.
Connect the 2 connectors and attach the 2 clamps to the engine room junction block.
(11) Install the engine room relay block cover.
34. INSTALL AIR SWITCHING VALVE ASSEMBLY (for Bank 2) Installation
35. CONNECT NO. 1 AIR HOSE Installation
36. INSTALL AIR SWITCHING VALVE ASSEMBLY (for Bank 1) Installation
37. INSTALL INTAKE MANIFOLD
(a) Install the intake manifold Installation.
38. INSTALL RADIATOR ASSEMBLY
(a) Install the radiator Installation.
39. ADD ENGINE OIL Replacement
40. ADD ENGINE COOLANT Service and Repair
41. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
42. INSPECT FOR OIL LEAK Replacement
43. INSPECT FOR COOLANT LEAK Testing and Inspection
44. CHECK ENGINE OIL LEVEL Testing and Inspection